Copyright 2016, FCA US LLC, All Rights Reserved (wah)
November 2016 Dealer Service Instructions for:
Safety Recall S07 / NHTSA 16V-047
Occupant Restraint Controller Module
2008 - 2009 (RT) Dodge Grand Caravan, Chrysler Grand Voyager,
Chrysler Town & Country
NOTE: This recall applies only to the above vehicles built at Windsor Assembly
plant (“R” in the 11th
VIN Position) through August 31, 2008 (MDH083119) or
St. Louis South Assembly plant (“B” in the 11th
VIN Position) through
August 28, 2008 (MDH 082814).
2009 (JC) Dodge Journey
NOTE: This recall applies only to the above built through August 30, 2008
(MDH 083000).
The Occupant Restraint Control (ORC) module on about 110,900 of the above
vehicles may experience a malfunction due to corrosion of the power supply
integrated circuit. This could result in an illuminated airbag warning lamp with the
possibility of no airbag deployment in a crash necessitating airbag deployment or
an inadvertent airbag deployment without an illuminated airbag warning lamp.
Either of these conditions could increase the risk of a crash and/or injury to front
seat vehicle occupants.
Models
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle
inventory. Dealers should complete this recall service on these vehicles before
retail delivery. Dealers should also perform this recall on vehicles in for service.
Involved vehicles can be determined by using the VIP inquiry process.
Subject
Safety Recall S07 – Occupant Restraint Control Module Page 2
The original ORC module must be replaced on all involved vehicles.
NOTE: Some vehicles involved in this recall were also involved in Safety Recall
K25. If not previously performed, Safety Recall K25 must also be performed at
this time.
WARNING: Failure to perform Safety Recall K25, if required, could allow
water from the HVAC unit to contaminate the new ORC module. Do not
complete Recall S07 without verifying on the VIP system that Safety Recall K25
has been performed.
Repair
Safety Recall S07 – Occupant Restraint Control Module Page 3
Part Number Description
CBL7S071AA ORC Module (JC models with SABC & Thorax)
CBL7S072AA ORC Module (JC models without SABC & Thorax)
CBL7S073AA ORC Module (JC models with SABC & Thorax
5-passenger calibration)
CBL7S07AAA ORC Module (RT models built on or before
02/25/2008 with SABC)
CBL7S076AA ORC Module (RT models built on or after
02/26/2008 with SABC)
CBL7S07BAA ORC Module (RT models built on or before
02/25/2008 without SABC)
CBL7S077AA ORC Module (RT models built on or after
02/26/2008 without SABC)
Definitions:
SABC = Side AirBag Curtain.
Thorax = Airbag located in the front seat seatback side cushion.
5-passenger calibration = Vehicles without sales code CAU.
7-passenger calibration = Vehicles with sales code CAU.
Each dealer to whom vehicles in the recall were assigned will receive enough
ORC modules to service about 20% of those vehicles.
Parts Information
Safety Recall S07 – Occupant Restraint Control Module Page 4
No parts return required for this campaign.
The following special tools are required to perform this repair:
NPN wiTECH micro pod II
NPN Laptop Computer
NPN wiTECH Software
Parts Return
Special Tools
Safety Recall S07 – Occupant Restraint Control Module Page 5
A. Replace ORC Module (RT Models)
WARNING: To avoid serious or fatal injury on vehicles equipped with side
curtain airbags, disable the Supplemental Restraint System (SRS) before
attempting any Occupant Restraint Controller (ORC) module diagnosis or
service. The ORC module contains a rollover sensor, which enables the
system to deploy the side SRS components in the event of a vehicle rollover
event. If an ORC module is accidentally rolled during service while still
connected to battery power, the side SRS components will deploy. Disconnect
and isolate the battery negative (ground) cable, then wait two minutes for the
system capacitor to discharge before performing further diagnosis or service.
This is the only sure way to disable the SRS. Failure to take the proper
precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury on vehicles equipped with
airbags, disable the Supplemental Restraint System (SRS) before attempting
any ORC module diagnosis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for the system capacitor to
discharge before performing further diagnosis or service. This is the only sure
way to disable the SRS. Failure to take the proper precautions could result in
accidental airbag deployment.
WARNING: To avoid serious or fatal injury, never strike or drop the
Occupant Restraint Controller (ORC) module, as it can damage the impact
sensor or affect its calibration. The ORC module contains the impact sensor,
which enables the system to deploy the Supplemental Restraint System (SRS)
components. If an ORC module is accidentally dropped during service, the
module must be scrapped and replaced with a new unit. Failure to observe
this warning could result in accidental, incomplete, or improper SRS
component deployment.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the
system capacitor to discharge.
CAUTION: Vehicles equipped with a MyGig radio (sales code REN or
REZ) must have the 30 amp fuse for the radio removed prior to
disconnecting or reconnecting the battery (for fuse location please consult
the vehicle’s fuse cover). Disconnecting and reconnecting the battery can
cause electrical spikes that may damage the MyGig radio. Removal of the
radio 30 amp fuse will prevent this from occurring.
Service Procedure
Safety Recall S07 – Occupant Restraint Control Module Page 6
2. If equipped, unlatch and remove
the center console located
between the two front seats.
3. Remove and save the six lower
storage bin retaining push pins.
4. Remove and save the storage bin
shroud.
5. Remove and save the cup holder.
6. Remove and save the right side
center stack bracket (Figure 1).
7. If equipped, carefully relocate the
right side floor air duct (Figure 2).
8. Vehicles equipped with Electronic Stability Program (ESP), remove and
save the ESP dynamics sensor from the right side of the ORC module mounting
bracket.
9. Disconnect the yellow instrument
panel wire harness connector and
body wire harness connector
from the ORC module yellow
electrical receptacles located on
the rearward facing side of the
ORC module (Figure 2).
NOTE: To disconnect the wire
harness connectors from the
ORC module, depress the
release tab and lift the lever
arm to the fully open position
on each connector.
Disconnecting the 36 pin
connector first will allow for
easier access when
disconnecting the 72 pin
connector.
Service Procedure (Continued)
Figure 1 – Right Side Center Stack Bracket
Figure 2 – Right Side Floor Air Duct
RIGHT SIDE CENTER STACK
BRACKET
YELLOW ORC MODULE WIRE HARNESS
CONNECTORS
RIGHT SIDE FLOOR
AIR DUCT
Safety Recall S07 – Occupant Restraint Control Module Page 7
10. Remove and save the three screws
that secure the ORC module to the
ORC mounting bracket.
11. Working from the right side of the
transmission tunnel, lift the original
ORC module far enough to
disengage the locating pins and
remove the original ORC module
from the bracket. Discard the
original ORC module.
12. Working from the right side of the
transmission tunnel, carefully
position the new ORC module to the
ORC module mounting bracket.
NOTE: When the ORC module is correctly positioned, the arrow on the
ORC module label will be pointed forward in the vehicle and the locating
pins on the bottom of the ORC module will be engaged into the locating
holes in the bracket.
13. Install and tighten the three screws that secure the ORC module to the ORC
module mounting bracket. Tighten the screws to 88 in. lbs. (10 N·m).
14. Reconnect the body wire harness connector and the instrument panel wire
harness connector to the ORC module yellow electrical receptacles located on
the rearward facing side of the module (Figure 3). Be certain that the latches on
both connectors are each fully engaged.
CAUTION: The lever arms of the wire harness connectors for the ORC
module MUST be in the unlatched position before they are inserted into
their connector receptacles on the ORC module or they may become
damaged.
15. Vehicles equipped with Electronic Stability Program (ESP), install the ESP
dynamics sensor onto the right side of the ORC module mounting bracket.
16. If equipped, place the right side floor air duct back into position (Figure 2).
Service Procedure (Continued)
Figure 3 – ORC Module
YELLOW ELECTRICAL
RECEPTACLES
ORC MODULE
LABEL
Safety Recall S07 – Occupant Restraint Control Module Page 8
17. Install the right side center stack bracket (Figure 1).
18. Install the cup holder.
19. Install the center stack lower storage bin and six retaining push pins.
20. If equipped, install the center console.
21. Do not reconnect the battery negative cable at this time. The Supplemental
Restraint System (SRS) verification test procedure must be performed
following ORC module replacement.
22. Perform the following Supplemental Restraints System Verification Test
procedure:
a. Be certain that the diagnostic scan tool contains the latest version of the
proper diagnostic software. Connect the scan tool to the 16-way Data Link
Connector (DLC).
b. Turn the ignition switch to the “ON” position.
c. Check to be certain that nobody is in the vehicle, then reconnect the battery
negative cable.
d. Using the scan tool, read and record the active (current) Diagnostic Trouble
Code (DTC) data.
e. Next, use the scan tool to read and record any stored (historical) DTC data.
23. New ORC modules are shipped in a “Locked Out” state and will set a B-2722
DTC “ORC LOCKED-ALL DEPLOYMENT DISABLED.” Perform the
following ORC Module Initialization procedure using the wiTECH scan tool:
a. Select the ORC icon from the vehicle view screen.
b. Select the “Miscellaneous Functions” tab.
c. Select “Initialize ORC” from the list.
d. Follow the screen prompts on the wiTECH screen.
NOTE: This will erase the fault codes and initialize the ORC module.
Service Procedure (Continued)
Safety Recall S07 – Occupant Restraint Control Module Page 9
24. Turn the ignition switch to the “OFF” position for 15 seconds, and then back to
the “ON” position. Observe the airbag indicator in the instrument cluster. The
airbag indicator lamp should illuminate for four to six seconds, and then go out.
This indicates that the SRS is functioning normally and that the repairs are
complete.
25. For vehicles equipped with a MyGig radio, install the 30 amp radio fuse.
26. For vehicles involved in Safety Recall K25, perform Safety Recall K25 if not
previously performed.
NOTE: Refer to Safety Recall K25 Dealer Service Instructions for the
service procedure, labor operation numbers, and labor time allowances.
WARNING: Failure to perform Safety Recall K25, if required, could allow
water from the HVAC unit to contaminate the new ORC module. Do not
complete this recall without verifying on the VIP system that Safety Recall
K25 has also been performed.
27. Return the vehicle to the customer.
Service Procedure (Continued)
Safety Recall S07 – Occupant Restraint Control Module Page 10
B. Replace ORC Module (JC Models)
WARNING: To avoid serious or fatal injury on vehicles equipped with side
curtain airbags, disable the Supplemental Restraint System (SRS) before
attempting any Occupant Restraint Controller (ORC) module diagnosis or
service. The ORC module contains a rollover sensor, which enables the
system to deploy the side SRS components in the event of a vehicle rollover
event. If an ORC module is accidentally rolled during service while still
connected to battery power, the side SRS components will deploy. Disconnect
and isolate the battery negative (ground) cable, then wait two minutes for the
system capacitor to discharge before performing further diagnosis or service.
This is the only sure way to disable the SRS. Failure to take the proper
precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury on vehicles equipped with
airbags, disable the Supplemental Restraint System (SRS) before attempting
any ORC module diagnosis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for the system capacitor to
discharge before performing further diagnosis or service. This is the only sure
way to disable the SRS. Failure to take the proper precautions could result in
accidental airbag deployment.
WARNING: To avoid serious or fatal injury, never strike or drop the
Occupant Restraint Controller (ORC) module, as it can damage the impact
sensor or affect its calibration. The ORC module contains the impact sensor,
which enables the system to deploy the Supplemental Restraint System (SRS)
components. If an ORC module is accidentally dropped during service, the
module must be scrapped and replaced with a new unit. Failure to observe
this warning could result in accidental, incomplete, or improper SRS
component deployment.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the
system capacitor to discharge.
Service Procedure (Continued)
Safety Recall S07 – Occupant Restraint Control Module Page 11
2. Using the following procedure,
remove the center console from
the top of the transmission tunnel:
a. Using a plastic trim stick,
carefully remove and save the
chrome shifter bezel (Figure 4).
CAUTION: Use extreme care
not to nick or scratch the
chrome trim bezel.
b. Remove and save the four
retaining screws located in the
center console storage bin (Figure 5).
c. Remove and save the plastic
push pins at the front lower
edge of the console.
d. Remove and save the center
console.
Service Procedure (Continued)
Figure 4 – Chrome Shifter Bezel
Figure 5 – Console Retaining Screws Located in Center Console Storage Bin
CHROME SHIFTER BEZEL
CENTER CONSOLE
CUP HOLDER
CENTER CONSOLE
CENTER CONSOLE RETAINING SCREW
LOCATIONS
Safety Recall S07 – Occupant Restraint Control Module Page 12
3. Using the following procedure,
remove and save the center
console cup holder.
a. Remove and save the center
console cup holder liner.
b. Remove and save the two
retaining screws located on
the bottom of the cup holder
pockets (Figure 6).
c. Remove and save the four
gear shift retaining nuts.
d. Relocate the gear shift
assembly slightly rearward
without disconnecting the gear
shift linkage or wiring.
e. Disengage the four push pins on the side of the cup holder panel (two on each
side) (Figure 7).
f. Partially remove the cup
holder assembly and
disconnect wiring.
g. Carefully remove the cup
holder assembly.
4. Remove and save the left side
panel.
Service Procedure (Continued)
Figure 6 – Center Console Cup Holder Retaining Screw Location
Figure 7 – Cup Holder Push Pins (right side shown)
CUP HOLDER RETAINING SCREW
LOCATIONS
PUSH PINS
Safety Recall S07 – Occupant Restraint Control Module Page 13
5. Remove and save the right
close-out panel (Figure 8).
6. Remove and save the right side
air duct (Figure 9).
7. Disconnect the instrument panel
wire harness connector,
followed by the body wire
harness connector from the
yellow Occupant Restraint
Controller (ORC) connector
receptacles located on the
rearward facing side of the
module.
NOTE: To disconnect the wire
harness connectors from the
ORC, depress the release tab and lift the lever arm to the fully open
position on each connector.
Service Procedure (Continued)
Figure 8 – Right Side Close-Out Panel
Figure 9 – Right Side Air Duct
GLOVE BOX DOOR
CLOSE-OUT
PANEL
RIGHT SIDE
AIR DUCT
ORC MODULE
INSTRUMENT
PANEL BRACE
INSTRUMENT
PANEL BRACE
Safety Recall S07 – Occupant Restraint Control Module Page 14
8. Remove and save the three bolts that secure the ORC to the ORC floor bracket.
9. Lift the ORC far enough to disengage the locating pins and remove the ORC
from the bracket (Figure 10).
10. Carefully position the new Occupant Restraint Controller (ORC) to the original
ORC bracket.
NOTE: When the ORC is correctly positioned, the arrow on the ORC label
will be pointed forward in the vehicle and the locating pins on the bottom
of the ORC will be engaged into the locating holes in the ORC floor
bracket.
11. Install and tighten the three bolts that secure the ORC to the ORC floor bracket.
Tighten the bolts to 108 in. lbs. (12.5 N·m).
Service Procedure (Continued)
Figure 10 – ORC Module
INSTRUMENT PANEL BRACE
ORC MODULE
Safety Recall S07 – Occupant Restraint Control Module Page 15
12. First reconnect the body wire harness connector, followed by the instrument
panel wire harness connector to the ORC connector receptacles located on the
rearward facing side of the module. Be certain that the latches on both
connectors are each fully engaged.
CAUTION: The lever arms of the wire harness connectors for the ORC
MUST be in the unlatched position before they are inserted into their
connector receptacles on the ORC or they may become damaged.
13. Install floor air duct.
14. Install right side close out panel.
15. Install left side panel.
16. Install the cup holder assembly onto the top of the floor panel transmission
tunnel.
17. Place gear shift assembly into position and install retaining nuts. Tighten the
nuts to 71 in. lbs. (8 N·m).
18. Do not reconnect the battery negative cable at this time. Continue with Section
C. SRS Verification Test.
Service Procedure (Continued)
Safety Recall S07 – Occupant Restraint Control Module Page 16
C. SRS Verification Test
1. During the following test, the battery negative cable remains disconnected and
isolated, as it was during the Supplemental Restraint System (SRS) component
removal and installation procedures.
2. Be certain that the diagnostic scan tool contains the latest version of the proper
diagnostic software. Connect the scan tool to the 16-way Data Link Connector
(DLC). The DLC is located on the driver side lower edge of the instrument
panel within a rectangular cutout in the lower instrument panel reinforcement,
just forward of the instrument panel steering column opening cover.
3. Turn the ignition switch to the ON position and exit the vehicle with the scan
tool.
4. Check to be certain that nobody is in the vehicle, then reconnect the battery
negative cable.
5. Using the scan tool, read and record the active (current) Diagnostic Trouble
Code (DTC) data.
6. Next, use the scan tool to read and record any stored (historical) DTC data.
7. If any DTC is found in Step 5 or Step 6, refer to the appropriate diagnostic
information.
8. Use the scan tool to erase the stored DTC data. If any problems remain, the
stored DTC data will not erase. Refer to the appropriate diagnostic information
to diagnose any stored DTC that will not erase. If the stored DTC information is
successfully erased, go to Step 9.
9. Turn the ignition switch to the OFF position for about 15 seconds, and then
back to the ON position. Observe the airbag indicator in the instrument cluster.
It should light from four to six seconds, and then go out. This indicates that the
SRS is functioning normally and that the repairs are complete. If the airbag
indicator fails to light, or lights and stays ON, there is still an active SRS fault
or malfunction. Refer to the appropriate diagnostic information to diagnose the
problem.
10. Continue with Section D. ORC Module Initialization.
Service Procedure (Continued)
Safety Recall S07 – Occupant Restraint Control Module Page 17
D. ORC Module Initialization
CAUTION: New ORC modules are shipped in a “Locked Out” state and will
set a B-2722 fault code “ORC LOCKED-ALL DEPLOYMENT DISABLED.”
Perform the following ORC Module Initialization procedure using the
wiTECH scan tool.
1. Select the ORC icon from the vehicle view screen.
2. Select the “Miscellaneous Functions” tab.
3. Select “Initialize ORC” from the list.
4. Follow the screen prompts on the wiTECH screen.
NOTE: This will erase the fault codes and initialize the ORC module.
5. Return the vehicle to the customer.
Service Procedure (Continued)
Safety Recall S07 – Occupant Restraint Control Module Page 18
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims
submitted will be used by FCA to record recall service completions and provide
dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace ORC module (RT Models) 08-S0-71-82 0.8 hours
Replace ORC module (JC Models) 08-S0-71-83 0.9 hours
Add the cost of the recall parts package plus applicable dealer allowance to your
claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete recall claim processing instructions.
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.
All involved vehicle owners known to FCA are being notified of the service
requirement by first class mail. They are requested to schedule appointments for
this service with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners
to update our records if applicable.
Completion Reporting and Reimbursement
Dealer Notification
Owner Notification and Service Scheduling
Safety Recall S07 – Occupant Restraint Control Module Page 19
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that
was obtained from the Department of Motor Vehicles of various states. Use of this information
is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services / Field Operations
FCA US LLC
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
Additional Information
This notice applies to your vehicle,
S07/NHTSA 16V-047
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep / RAM Dealership
2. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent can confirm part
availability and help schedule an
appointment
3. Visit our Recall Website,
recalls.mopar.com or scan below.
You can find your nearest dealer and
review all your scheduling options
from this website. You will be asked
to provide your Vehicle Identification
Number (VIN) to protect and verify
your identity. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall S07.
IMPORTANT SAFETY RECALL OCCUPANT RESTRAINT CONTROL MODULE
Dear [Name],
This notification is being sent to you in accordance with the National Traffic and Motor
Vehicle Safety Act.
FCA has decided that a defect, which relates to motor vehicle safety, exists in certain [2008-
2009 Dodge Grand Caravan, Chrysler Grand Voyager, Chrysler Town & Country and 2009 Dodge
Journey] vehicles.
It is extremely important to take steps now to repair your vehicle to ensure the safety of you
and your passengers.
WHY DOES MY VEHICLE NEED REPAIRS?
The Occupant Restraint Control (ORC) module on your vehicle [1]
may experience a
malfunction due to corrosion of the power supply integrated circuit. This could result in
either, an illuminated airbag warning lamp with the possibility of no airbag deployment in a
crash necessitating airbag deployment, or an inadvertent airbag deployment without an
illuminated airbag warning lamp.
Either of these conditions could increase the risk of a crash and/or injury to front seat vehicle
occupants.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE
FCA will repair your vehicle [2]
free of charge (parts and labor). To do this, your dealer will
replace the Occupant Restraint Control module. In addition, your dealer will require your
vehicle for proper check-in, preparation, and check-out during your visit. Your time is
important to us; please be aware that these steps may require more time. The estimated repair
time is one hour. We recommend that you schedule a service appointment to minimize your
inconvenience. Please bring this letter with you to your dealership.
TO SCHEDULE YOUR FREE REPAIR CALL 1-800-853-1403
OR YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank
you for your attention to this important matter.
Customer Assistance/Field Operations
Fiat Chrysler Automobiles US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
VEHICLE PICTURE
LOGO
QR Code
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-
8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371